Casting station for battery fabricating machine

ABSTRACT

An improved molding station for a battery fabricating machine of the type having an element carrier for transferring battery elements composed of plates and separators between loading, fluxing, casting and unloading stations by means of vertical movement at the stations and rotational movement therebetween, the casting station having cavities therein for molding straps and posts to the lugs of the battery plates, the posts having studlike projections on the face thereof spaced from the straps, characterized in that the casting station has movable mold cavity walls to permit the axial withdrawal of the cast post and strap structure from the cavity as the element carrier is axially lifted at the casting station preparatory to moving to the unloading station.

United States Patent John E. Farmer Farmer Mold and Machine Works, Inc., 12034 South Emerald, Chicago, 111. 60628 743,648

July 10, 1968 Nov. 2, 1971 [72] Inventor App]. No, Filed Patented CASTING STATION FOR BATTERY FABRICATHNG MACHINE 2 Claims, 13 Drawing Figs.

U.S. Cl 164/333, 164/108,164/109,164/D1G. 1, 249/161, 249/83, 249/91 Int. Cl ..l 32 2d17/24, B22d 19/00 Field of Search 249/162, 161 US, 170 US, 83, 91; 164/108, 109,DIG. 1,

References Cited UNITED STATES PATENTS 8/1965 liuttke 7,89%?7/1933W53/EFI 164710935 1,720,357 7/1929 Willard... 164/322 2,107,041 2/1938 Luhrman.... 164/322 X 1,809,289 6/1931 Stecker 164/314 X Primary Examiner.l. Spencer Overholser Assistant Examiner-V. K. Rising Attorney-Hofgren, Wegner, Allen, Stellman and McCord ABSTRACT: An improved molding station for a battery fabricating machine of the type having an element carrier for transferring battery elements composed of plates and separators between loading, fluxing, casting and unloading stations by means of vertical movement at the stations and rotational movement therebetween, the casting station having cavities therein for molding straps and posts to the lugs of the battery plates, the posts having studlike projections on the face thereof spaced from the straps, characterized in that the casting station has movable mold cavity walls to permit the axial withdrawal of the cast post and strap structure from the cavity as the element carrier is axially lifted at the casting station preparatory to moving to the unloading station.

PATENTEDNUV 2 I97! SHEET 2 [IF 6 CASTING STATION FOR BATTERY FABRICATING MACHINE BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to battery fabricating machines and more particularly to an improvement in the casting station of such machines.

2. Description of the Prior Art Until recently, the common method of assembling posts, straps and plates of a storage battery has been by the so-called "burning" process. Simply stated, this meant that the post was cast separately and then welded to a strap which was welded across the lugs on the battery plates. Recently the so-called cast-on method of battery plate assembly has come into use. By this method, the lugs of the battery plates are dipped into a mold cavity containing molten lead so that the straps and posts are fused to the lugs. When the molten lead is cooled, the adhered straps and posts are withdrawn from the mold cavity. Mechanisms for carrying out the cast-on method of battery assembly have been disclosed in Vieth U.S. Pat. No. 2,799,905, issued July, 1957; Sabatino et al. U.S. Pat. No. 3,253,306, issued May 31, 1966; as well as my own copending application entitled Battery Element Fabricating Machine," filed June 29, I967, Ser. No. 650,119, now U.S. Pat. No. 3,504,731.

Generally speaking, in the aforementioned structures the battery plates and separators are held in a carrier and moved to a casting station in alignment with a mold block. At the casting station the carrier is moved axially to bring the lugs of the plates into the several cavities of the mold. Plates are held in the carriers in groups with separators between each of the plates and with the alternate plates arranged so that the lugs are on opposite sides of the group. When the lugs enter the mold cavity, they come in contact with the molten lead of the strap portion of the cavity and are fused therewith so that the strap portion bridges the several lugs on each side of the group, thereby electrically joining alternate plates. Each group has a post formed on one end of the strap, the two posts facing in opposite directions. The post portion of each mold cavity extends generally perpendicularly inwardly of the mold from the strap portion, at one end of the strap. When the groups are placed in the battery, two posts of adjacent groups face each other in the battery and are joined across the battery partition to electrically connect the cells of the batteries.

Recently, the concept of through partition" joining of posts of the battery groups has become popular. In this construction, the posts are joined by forming an opening in the partition which separates the cells and electrically connecting the posts through this opening instead of bridging the partition at the top thereof. This means that shorter posts can be formed on the battery groups thereby saving lead and reducing the weight of the batteries. Such a construction is shown in FIG. 2 of Sabatino, U.S. Pat. No. 3,242,012. In order to facilitate this type of connection, battery posts may be formed with a studlike projection which faces outwardly from the group, medially of the face of the post. Problems have arisen in attempting to produce this type of structure by the cast-on method, in that the mold cavity must be recessed or "undercut to form the stud, yet the resultant casting must be axially withdrawn from the cavity as the carrier moves vertically from the casting station following completion of the casting step and preparatory to advancing to the next station. As a result, heretofore there has been no satisfactory means for forming the post portion with such an outwardly facing stud on the face thereof by the cast-on method.

SUMMARY OF THE INVENTION This invention is directed, in brief, to an improved casting station for battery-fabricating machines for assembling battery plates and separators in groups by the cast-on method and for forming the groups with posts having studlike projections medially of the face thereof to facilitate "through partition" joining of adjacent posts of battery groups, the mold cavities having movable elements for first forming the strap and post portions with the aforesaid projecting stud on the face of each of the posts, and then secondly moving away from the first forming position to permit withdrawal of the cast posts and straps from the mold cavities as the battery groups are removed therefrom preparatory to advancing to the next station. The best mode currently contemplated for carrying out this invention is to make that wall of each cavity in which the studlike projection is formed movable away from the remainder of the cavity following completion of the casting. In the illustrated embodiment, the wall is pivoted intermediate its ends and cam actuated so as to be swingable about a horizontal axis following completion of the casting to a position wherein the strap, post, and studlike projection on the post may be moved axially out of the cavity free from interference with any portion of the cavity, particularly with the wall of the cavity in which the studlike projection is formed.

BRIEF DESCRIPTION OF THEDRAWINGS FIG. 1 is a top plan view of a battery element fabricating machine embodying the casting station of this invention;

FIG. 2 is a fragmentary enlarged top plan view of the casting station of this invention;

FIG. 3 is a section view of the casting station of this invention taken generally along the lines 3--3 of FIG. 2;

FIG. 4 is a side elevational view of the mold block portion of the castingstation of this invention;

FIG. 5 is a section view, taken generally along the lines 5-5 of FIG. 4, and being substantially a bottom plan view of the mold block of the casting station of this invention;

FIG. 6 is a section view taken generally along the lines 6-6 of FIG. 2;

FIG. 7 is a fragmentary enlarged view, partially broken away in section, showing the cavities and movable wall portions thereof of the casting station of this invention in greater detail;

FIG. 8 is a fragmentary sectional view of a portion of the structure shown in FIG. 6, showing the cam actuating components for moving the movable wall sections of the mold cavity of this invention in greater detail;

FIG. 9 is a fragmentary view of a battery plate and separa' tor, showing a strap and post cast to the lug of the battery plate, the post being of the type having a studlike projection medially of the face thereof;

FIG. 10 is a fragmentary sectional view through two adjacent cells of a battery showing the connection of adjacent posts through an opening in the partition which separates the cells;

FIG. 11 is a side elevational view of the mold support of the casting station of this invention;

FIG. 12 is a top plan view of the mold support of the casting station of this invention; and

FIG. 13 is an end elevational view of the mold support of the casting station of this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT General Machine Structure In FIG. 1 there is shown a battery element fabricating machine or battery element assembly machine 10 which is described fully in my copending application entitled Battery Element Fabricating Machine" Ser. No. 650,119. filed June 29, 1967. Briefly, this type of machine is intended for use in joining a number of battery plates 12 and interposed separators 14 into groups 16 by forming straps I3 and posts 20 on the lugs 22 of the plates, as best seen in FIGS. 9 and W. The post 20 may have outwardly projecting studs 21 medially of the face thereof for assisting in joining adjacent lugs through an opening 21a in a partition 21b between battery cells. Generally battery plates 12 are gridlike structures with an electrolytic activated paste bonded to the grids. The lugs 22 project outwardly near one side of the top of the plate.

The battery element fabricating machine It) includes a loading station 24 wherein the plates and separators are loaded; a fluxing station 26 wherein flux from a fluxing plot 26a is applied to the lugs of the plate; a casting station or molding station 28 wherein molten lead 29, (FIG. 3) fed by pressure flow from a lead vat 29a through conduit means 29b to the station is cast on the previously fluxed lugs 22; and an unloading station 30 wherein the completed groups 16 are dropped onto a shelf or other surface from which the groups 16 may be carried to be assembled into a battery casing.

The machine It) is provided with a frame including a plurality of upright legs 32. Housing means encloses the frame and includes a plurality of side panels and top cover 36. The machine has a central column 38 which is both vertically movable with respect to the frame and rotatable as well. Arms 39 extend radially outwardly from a hub 390 connected to the top of column 38. Each arm 39 supports hoppers, baskets or group carriers 40 that extend radially outwardly from the arms and are adapted for holding the battery plates and separators in groups as the several operations are pefiormed at the different stations. The carriers 40 are rotatable relative to the arms 39 and are movable with the column 38.

Group Carriers As described in detail in my aforementioned copending application, each of the carriers 40 includes an outwardly opening U-shaped member or box comprised of parallel sidewalls 42 spanned by a rear wall 44. A plurality of partitions 45 extend transversely between the sidewalls 42 to generally define plate and separator confining areas or compartments.

Further included in the carrier assembly is a telescopically related sleeve member comprising a pair of side panels 46 joined together by a bridge member 47 at the rear thereof. A spring (not shown) is fixed to the side panels 46 of the sleeve and to the sidewalls 42 of the box member to normally urge the sleeve and box together in a retracted plate gripping position as shown at the fluxing station 26, casting station 28, and unloading station 30.

The side panels 46 include upper and lower inwardly extending flanges which include plate gripping ribs 48 that are movable toward and away from the partitions 45 as the sleeve member is moved relative to the box, allowing the ribs to alternately grip plates and separators between the ribs 48 and the partitions 45 to thereby hold groups in the carrier, or to release the gripping engagement to permit the loading and unloading of groups from the baskets. In the plan view of FIG. 1 the carrier 40 at the loading station 24 is shown in a group I loading or releasing position and is moved to this position by actuation of cylinder 49 which extends rod 50 that moves arm 51 which, in turn, pushes against the bridge member 47, thereby moving the sleeve relative to the box and moving the plate-gripping ribs 48 away from the partitions 45.

The main drive system, the group carriers, the means by which the group carriers are rotated, moved between the opened and closed positions, the means by which plates are loaded and aligned in the group carriers at the loading station as well as the control of the functional components and operation of the battery machine 10 are described fully in detail in my aforementioned and copending application Ser. No. 650,] 19, and will not be described further herein.

Casting Station-Lead Supply The conduits 29b which supply lead from the vat 29, extend into manifolds 54 at opposite sides of mold block 56 at the casting station 28. Each manifold has a longitudinally extending bore 58 through which the lead flows, and a temperature sensing means 58a is positioned in at least one of the manifold bores for sensing the temperature of the lead. Heaters 58b and 580 are provided in the manifold, preferably diametrically opposite bore 58 to maintain the molten lead at a high temperature, such as 900 F. Ducts 60 lead from the bore 58 of each manifold 54 and are in communication with each valve block 62, particularly the valve passages 64 thereof. A valve seat 66, is provided in each valve block 62 intersecting the valve passage 64. A cock 68 is seated in each seat 66. Cock 68 has a through passage 70 so that the valve passage 64 may be selectively opened and closed by aligning the passage 70 of cock 68 with the passage 64 of block 62, or by rotating the same out of alignment therewith. Preferably passage 64 terminates in an opening 72 formed in one side of each valve block 62.

Each cock 68 has a projection 74 which extends outwardly from the valve block 62. Projection 64 is connected to a link 76 pivoted at 78 to an arm 80. Arm 80 has a wing nut 82 at the lower end thereof by means of which a connector 84 is secured thereto. Connector 84 is pivoted to connecting arm 86 which is secured to a rod 88 rotatable in a sleeve 90 secured to the machine. Rotation of sleeve 90 by means described in my aforementioned copending application causes, through the aforedescribed linkage, rotation of the cock 68 to open and close the valve passage 64 in each valve block 62 and thereby selectively supply or shut off the flow of lead through the valve block.

Casting Station Mold Block Mold block 56 is made up of a plurality of mold elements 94 and interposed spacers 96 that are held together in tandem fashion by tie rods 98 which extend through the opposite end pieces 100. Each mold element 94 is a generally rectangular member of suitable mold material, such as steel, and has tie rod openings 102 for receiving the tie rods 98 which extend therethrough; water line openings 104 for circulating water from water lines 105; and opening I06 for receiving temperature sensor line 106a. Each mold element further has a U- shaped notch 108 generally centrally located in the top thereof and a wide angle U-shaped notch 110 at the bottom thereof. Feet ll 12 extend outwardly from opposite sides of the bottom of each mold element 94 and are provided with perpendicularly related, smoothly machined, bottom surfaces I14 and smoothly machined upstanding side surfaces 116. As will be explained later, these surfaces assist in aligning the mold block at the casting station.

Spacer elements 96 are also generally rectangular members of hard material, such as steel and are also provided with aligned tie rod, water and temperature sensor openings, (not shown) but are narrower than the mold members 94 (as best seen in FIGS. 2 and 5) and do not have the analogous feet members 112. The spacers are also notched at top and bottom in like manner as the mold elements 94!.

End members 100 are also provided with aligned tie rod, water line and temperature sensor openings (not shown) and are further provided with a depending web H8 in the area adjacent the bottom notch 110 of the mold elements members 94. These webs 118 have a pair of openings 120 for rotatably receiving cam operating rods 122a and l22b which extend the length of the underside of the mold block, as best seen in FIGS. 4 and 5.

Each cam-operating rod supports alternately disposed, oppositcly facing, cam fingers 124a and I24b respectively, having opposed inclined cam surfaces 126a and 126b, respectively, which face upwardly into the space between pairs of mold elements 94 adjacent spacers 96, as best seen in FIGS. 4 and 7. As viewed in FIG. 5, the leftmost rod 122a mounts alternately arranged cam fingers 124a which extend to the right side of the mold block and the rightmost rod l22b mounts alternately arranged cam fingers l24b which extend to the left side of the mold block in between each rightwardly extending cam finger 124a. Each rod 122a and 122!) has a laterally extending arm 128a and 12612, respectively, fixed on the inner end thereof, each arm terminating in a pad 130a and 13012, respectively, at its free end. Pads 130a and Bob are in a position to be engaged by screw adjustable pads 132a and l32b respectively, carried in a plate 134 mounted on the end of a rod 136 of piston and cylinder device 138. As the piston and cylinder device 138 is actuated and rod 136 extends, pads 130a and 130b and 132a and 132b engage and by the resulting scissor action, as best seen in FIGS. 6 and 8, rotate rods 122a and 12211 to move cam fingers 124a and 12411 upwardly at the free ends thereof in the space between mold elements 94.

A plurality of mold cavities 140 face outwardly from the top of the mold block and include a shallow, generally horizontally extending strap portion 142 and a deep, generally vertically extending post portion 144. The outer face of each post cavity M4 is bounded by a fingerlike movable wall 146, each of which has a stud recess 148 formed therein facing inwardly to post cavity 144. Each movable wall 146 has a smooth face 150 which faces inwardly to each cavity portion 144 and abuts the adjacent surfaces of each mold element 94 in tight sealing engagement therewith. Each movable wall 1 16 is pivoted intermediate its ends at 152 to the spacer elements 96 and at the lower end a spring 154 is interposed between each wall 146 and the adjacent mold elements 94 to normally hold the movable wall 146 in a closed position, as best seen in FIG. 4.

The lower ends of the movable walls 146 have cam surfaces 156 which normally abut the cam surfaces 126 of the cam fingers 124a and 12412. When cam-operating rods 122a and 12212 are rotated responsive to actuation of cylinder 138, upward movement of the fingers 124a and 124b causes the movable walls 146 to pivot in opposition to springs 154 and swing to an open position, as best seen in FIG. 7. When moved to this position, the stud recess 148 of each movable wall 146 is swung clear from the cast stud 21 formed on each post portion 20, thereby permitting withdrawal of the cast strap 18 and post 20 from each cavity. After the group carriers have lifted the groups with the cast strap and post portions on the battery lugs from the cavities, cylinder 138 is deactivated, rods 122a and 12212 reversely rotate causing fingers 124a and 124k to move downwardly, and permitting springs 154 to urge the movable walls 146 back to the closed position, ready for the introduction of molten lead into cavities 140 for the next casting cycle.

Opposite ends of the mold block are provided with terminal cavities 158, the bottoms of which are defined by a movable pusher 160 connected to a plate 162 with spring means 164 interposed between the pusher and the bottom of the mold. Plate 162, in turn, is connected to an upstanding rod 166 which extends from a cylinder (not shown) for assisting in pushing the cast groups outwardly from the mold when the group carriers are lifted, as explained in detail in my aforementioned copending application. Pusher rods 168 are also connected to plate 162 and extend upwardly generally along the longitudinal centerline of the mold block 56 through spaced mold elements 94 to connection with separator pusher bar 170. Bar 170 extends longitudinally of the mold block in the areas of the notches 108 at the top of the mold elements. When plate 162 is pushed upwardly by rod 166, pusher bar 170 pushes upwardly on the groups in engagement with the separators 14 to further assist in lifting the cast battery groups outwardly of the mold block as the group carrier raises, preparatory to advancement to the next station.

Casting Station- Mold Block Support The mold block 56 is mounted in a mold support 172 extending outwardly from one side of the machine 10. Mold support 172 includes a generally flat mounting plate 174 with a pair of outwardly extending spaced arms 176a and 176b, each of which has a depending wall portion 178a and 178b, respec tively, for assisting in supporting some of the components of the casting station, such as the sleeve 90. Each arm 176a and 1761) has channels or guideways 150a and 1801: respectively, in the upper surface thereof, including the horizontal guide surfaces 182a and 1112b and the lateral guide surfaces 184a and 18411. These guide surfaces are intended to precisely mate with the surfaces 11d and 116 of the feet 112 of mold elements 94, as best seen in FIG. 3. For example, the surfaces 116 are in close sliding abutment between the lateral guide surfaces 184a and 184b so that when the mold block is mounted in the mold support it is held against any lateral deviation or movement. Also the surfaces 114 of each mold element 94 are in precise sliding engagement with the horizontal surfaces 182a and 182b of the mold support so that the mold block is held at a precise elevation with respect to the rest of the mechanism at the casting station.

Casting Station-Mold Block Mounting A mounting arrangement is provided for positively holding the mold block on the mold support. This mounting arrangement includes a first pin receiving element or yoke 186 on the ,outer or rear end of the mold block 56, the yoke opening being angularly oriented relative to the block so as to orient a pinlike fastening member in a direction facing toward the machine, or the other end of the block. Preferably the yoke 186 is mounted on block 56 by a bolt means 1860. The pinlike fastening member preferably is mold block mounting bolt 188 which, in the assembled relationship, extends through another pin fastener receiving means which is oriented to receive the pin fastener in a direction facing toward the machine. ln the preferred embodiment, the other pin fastener receiving means takes the form of an eye 190 having an opening 1900 on an axis which is coaxial with the opening in the yoke 186, the eye 190 being connected to element 192 spaced from the mold block 56. The bolt 188 is held in assembled relationshipwith the aid of a suitable nut means, such as the wing nut 194 threaded on the end of the bolt 188 which extends through the opening 190:: of eye 190.

As seen in FIG. 4, the machine is provided with a carrier aligning pin 196 which is intended to seat in a mating indentation in the group carriers for assisting in registering the group carriers relative to the casting station when the carriers descend therein, as explained in detail of my copending application. The carrier aligning pin 196 is mounted on the top of a bracket 198. To assist in holding the mold block on the mold support, bracket 198 is provided with an inclined underside 200 which is intended to abut the tapered end 202 of adjusting screw 204 threadably received in the forward end of the mold block. The mold block 56 may be assembled on the mold support in proper registration with the battery lugs held in the group carriers by merely sliding the mold block on guideways 180a and lb until the adjusting screw 204 abuts the underside 200 of bracket 198. The mold cavities may be adjusted to and fro relative to the frame and relative to the lugs of the group carriers by threading the adjusting screw 204 in or out relative tothe mold block. When the desired setting of the adjusting screw has been made, the mold block is locked in place by extending bolt 188 through yoke 186 with the opposite end of the bolt through the eye 190 and securely tightening the bolt means of a wing nut.

Because the bolt extends downwardly and forwardly the mold block is clamped tightly on the guideway horizontal guide surfaces 182a and l82b and also snugly urged in abutment with the inclined underside 200 of bracket 198, thereby being securely locked against movement in any direction. Removal and replacement of the mold block for casting posts and straps of slightly different configuration is easily accomplished by loosening the wing nut 194, withdrawing the bolt from the yoke, and reversely sliding the mold block outwardly from the mold support, followed by reinsertion of a different mold block and assembly in the manner previously described.

This invention provides a means for forming battery posts and straps on the lugs of battery plates by the cast-on method, wherein the battery posts have outwardly projecting studs to facilitate the joining of posts of adjacent cells by the through partition method. This is accomplished by movably mounting that wall of the post cavity which is recessed to form the post stud. The casting station is further provided with auxiliary means for moving the completed cast: from the mold block. This auxiliary means taking the form of a bar 170 which pushes upwardly against the plate separators at the same time that the pushers are moved upwardly against the post and simultaneous with the vertical withdrawal of the carrier 40 from the casting station. Furthermore, the mounting arrangement afforded by the mold support and complementary surfaces on the mold block, together with the means for locking the mold block on the mold support, provide a means by which different mold blocks may be easily interchanged at the casting station and quickly and precisely mounted in proper registration for the casting operation.

The foregoing detailed description has been for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as some modifications may be obvious to those skilled in the art.

Iclaim:

l. A casting station for a battery-facricating machine comprising; means for supplying molten metal to the casting station; a mold block at the casting station in communication with the molten material supply means; mold cavities in the mold block to which the molten material is supplied, said cavities having bottom and sidewalls and an open top for permitting insertion and withdrawal of lugs of battery plates therefrom, one of said sidewalls being pivoted intermediate its ends and having a recess therein which faces to the interior of the cavity with the said one sidewall being movable from a closed cavity enclosing position for receiving molten material,

to an open position for permitting withdrawal of a completed casting therefrom: means for urging the movable wall to the closed position; the movable wall having a cam surface thereon in opposition to the means for urging the wall to the closed position; a cam member at the casting station normally positioned adjacent the cam surface of the movable wall and movable between a retracted, wall closed, position and, an extended, wall open, position, and a plurality of operating rods extending the length of the mold block with the cam members connected to each rod, said rods being in a generally side-byside relationship with the cam members of one rod extending across the cam members of the other rod, and the cam members of the other rod extending across the one rod so that rotational movement of the rods causes substantially linear movement ofthe cams.

2. The casting station of claim 1 wherein each rod is provided with anns at one end which extend in the same direction as the cam member associated with that rod, whereby the application of linear movement to the ends of the arms causes rotational movement to the operating rods and linear movement of the cam members. 

1. A casting station for a battery-facricating machine comprising; means for supplying molten metal to the casting station; a mold block at the casting station in communication with the molten material supply means; mold cavities in the mold block to which the molten material is supplied, said cavities having bottom and sidewalls and an open top for permitting insertion and withdrawal of lugs of battery plates therefrom, one of said sidewalls being pivoted intermediate its ends and having a recess therein which faces to the interior of the cavity with the said one sidewall being movable from a closed cavity enclosing position for receiving molten material, to an open position for permitting withdrawal of a completed casting tHerefrom: means for urging the movable wall to the closed position; the movable wall having a cam surface thereon in opposition to the means for urging the wall to the closed position; a cam member at the casting station normally positioned adjacent the cam surface of the movable wall and movable between a retracted, wall closed, position and, an extended, wall open, position, and a plurality of operating rods extending the length of the mold block with the cam members connected to each rod, said rods being in a generally side-by-side relationship with the cam members of one rod extending across the cam members of the other rod, and the cam members of the other rod extending across the one rod so that rotational movement of the rods causes substantially linear movement of the cams.
 2. The casting station of claim 1 wherein each rod is provided with arms at one end which extend in the same direction as the cam member associated with that rod, whereby the application of linear movement to the ends of the arms causes rotational movement to the operating rods and linear movement of the cam members. 